Download Scotsman CMS1202R Service manual
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CMS1202R INTRODUCTION To the owner or user: This service manual is intended to provide you and the maintenance or service technician with the information needed to install, start up, clean, maintain and service this ice system. Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 For the Installer Location & Assembly Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 For the Electrician . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 For the Plumber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Final Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Initial Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Freeze Cycle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Harvest Cycle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Component Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Parts Lists and Wiring Diagrams are located in the center of this manual, printed on yellow paper. September 1993 Page 1 CMS1202R FOR THE INSTALLER The CMS1202R will fit the following Scotsman ice storage bins: A remote condenser and precharged tubing kit are required to assemble this ice system. • BH900 • BH1000 (with bin top KBT21) • BH1360 The normal finish for the machine is enamel sandalwood. An optional stainless steel panel kit (SPKCM1402) can be field installed. It contains a stainless steel top, left side panel, an overlay right side panel, and front panel. and it will stack (with kits) onto the following ice machines: • CMS1402 (with stacking kit KSCMS48) • CMS1202 (with stacking kit KSCMS48) This manual covers both A and B models (B models have 2 front panels). Scotsman Ice Systems are designed and manufactured with the highest regard for safety and performance. They meet or exceed the standards of U.L., N.S.F., and C.S.A. Scotsman assumes no liability or responsibility of any kind for products manufactured by Scotsman that have been altered in any way, including the use of any parts and/or other components not specifically approved by Scotsman. Scotsman reserves the right to make design changes and/or improvements at any time. Specifications and designs are subject to change without notice. Model Number Dimensions (without bin) W" x D" x H" Basic Electrical Refrigerant Minimum Maximum Refrigerant Condenser Type Circuit Fuse Charge** Type Ampacity* Size R-22 48 x 243⁄8 x 271⁄2 208-230/60/3 R-22 CMS1202RE-32B 48 x 243⁄8 x 271⁄2 208-230/60/1 R-22 CMS1202RE-3B 15.2 20 256 oz. Remote Air 21.2 30 256 oz. Remote Air * Minimum Circuit Ampacity is used to determine wire size and type per the National Electric Code. ** The unit is shipped with the full charge in the receiver. For re-charging purposes, if the nameplate charge is different than this number, go by the nameplate. Use Scotsman remote condenser RC1422. Use precharged tubing kit RT2225 (25’) or RT2240 (40"). This ice system (except remote condenser) is designed to be installed indoors, in a controlled environment. MINIMUM MAXIMUM 0 50 F. 1000F. Water Temperature 0 40 F. 1000F. Water Pressure 20 psi 80 psi Voltage -5% +10% Air Temperature September 1993 Page 2 CMS1202R FOR THE INSTALLER: Location & Assembly Location: After uncrating and inspection, the unit is ready for installation. It is important that the machine be installed in a location where it has enough space around it to be accessible for service. Try to avoid hot, dirty and crowded locations. Be sure that the location for the machine is within the envrionmental limitations. Storage Bin: Tip the storage bin on its back, using parts of the carton to protect the exterior finish. Install the legs, use a heavy duty leg kit if stacking two ice machines on one bin. ICE MACHINE AND BIN ASSEMBLY 1. Arrange for proper electric, water and drain. See instructions for the plumber and for the electrician. 2. After mounting the legs, position the ice storage bin in the selected location: Note: Allow enough space to the left and back to service the machine. Do NOT push the bin into postion, instead, lift it there. Pushing a bin may damage the legs and leg mounts. Level the bin in both the front to rear and side to side directions by adjusting the leg levelers. 3. Inspect the bin top mounting gasket which should be flat, with no wrinkles, to provide a good water seal when the cuber is installed on top of the bin. Ice Maker: Install the modular cuber on top of the bin using care to be sure a good seal is made between the two cabinets. Use of a mechancial lift is recommended. Align the holes in the bottom rear of the cabinet to mate with the two mounting holes on the top rear of the bin. Use bolts and straps found on the back of the ice machine to secure the ice machine to the bin. When alignment and leveling are completed, tighten the bolts to secure the mounting straps. Remove the front panel, and remove the evaporator shipping brackets and hardware. September 1993 Page 3 SHIPPING BRACKETS CMS1202R FOR THE INSTALLER: Location & Assembly Stacking Instructions When stacking two units, remove the top panel and the evaporator cover from the lower icemaker. (The top removed from the lower icemaker will no longer have any function.) Carefully lift the uncrated top unit onto the bottom one and align the two cabinets. Use of a mechanical lift is recommended for this step. At the back of the two icemakers, bolt the upper icemaker cabinet to the lower icemaker cabinet using the mounting straps and bolts from the hardware package. A stacking kit is required to interconnect the CMS ice level controls. STACKING TRIM STRIP - PART OF KSCMS48 STACKING KIT EVAPORATOR COVER September 1993 Page 4 CMS1202R FOR THE INSTALLER: Remote Condenser Locate the condenser as near as possible to the interior location of the ice maker. Precharged Line Routing Location of the condenser is limited by the specific length of precharged refrigerant tubing supplied for the application. The pre-charged tubing connects the icemaker to the remote condenser. The condenser must be above the ice maker. Do not connect precharged tubing until all routing and forming of the tubing is complete. See the coupling instructions for connecting instructions. Select the best available location, protecting the condenser from extremes of dirt, dust, and sun. 1. Each set of precharged refrigerant lines consists of a 3/8 inch diameter liquid line, and a 1/2 inch diameter discharge line. Both ends of each line have quick connect couplings, the end without access valves goes to the icemaker. Meet all applicable building codes. Roof Attachment: Install and attach the remote condenser unit to the roof of the building, using the methods and practices of construction that conform to the local building codes, including having a roofing contractor secure the condenser to the roof. /////////////////////////////CAUTION/////////////////////////////// //////////////////////////////////////////////////////////////////////////// Note: The openings in the building ceiling or wall, listed in the next step, are the minimum sizes recommended for passing the refrigerant lines through. 2. Have the roofing contractor cut a minimum hole for the refrigerant lines of 1.75". Check local codes, a separate hole may be required for the electrical power to the condenser. /////////////////////////////CAUTION///////////////////// /////////// DO NOT KINK OR CRIMP REFRIGERANT TUBING WHEN INSTALLING IT. ////////////////////////////////////////////////////////////////// ////////// REFRIGERANT CONNECTIONS 3. Route the refrigerant lines through the roof opening. Follow straight line routing whenever possible. Any excess tubing MUST be retained within the building. LOCATE CONDENSER NO LOWER THAN ICE MACHINE 4. Spiral any excess length of pre charged tubing inside the building. Use a horizontal spiral (as illustrated) to avoid any traps in the lines. 5. Have the roofing contractor seal the holes in the roof per local codes. TYPICAL INSTALLATION September 1993 Page 5 CMS1202R FOR THE INSTALLER: Coupling Instructions ////////////////////////////////CAUTION///////////////////////////////// The couplings on the sets of precharged lines are self sealing when installed properly. Carefully follow the instructions: //////////////////////////////////////////////////////////////////////////////// Initial Connections: 1. Remove the protector caps and plugs. Wipe the seats and threaded surfaces with a clean cloth to be certain that no foreign matter remains on them. • The 3/8 inch liquid line goes to the icemaker fitting marked “liquid line.” Final Connections: 3. Begin tightening the couplings together by hand, then using two wrenches (it is important that ONLY the nut on the precharged lines be turned, the other parts of the couplings must NOT be allowed to turn or the process will tear out the diaphragms and they will be loose in the refrigeration system) tighten the coupling until it TIGHTENING THE QUICK CONNECTS 2. Lubricate the inside of the couplings, especially the O-Rings with refrigerant oil. • The 1/2 inch discharge line (schrader valve end) goes to the remote condenser fitting marked “discharge line”. • The 3/8 inch liquid line (schrader valve end) goes to the remote condenser fitting marked SCHRADER VALVES bottoms out or a definite increase in resistance is felt. 4. Using a marker or pen, mark a line lengthwise from the coupling union nut to the bulkhead. Then tighten the coupling and additional 1/4 turn. As the nut turns, the line will show when 1/4 turn is made. “liquid line”. • The 1/2 inch discharge line goes to the icemaker fitting marked “discharge line”. DISCHARGE LINE 5. After all connections are made, and after the king valve has been opened, check the couplings for leaks. LIQUID LINE INSULATION September 1993 Page 6 CMS1202R FOR THE ELECTRICIAN SEE NAMEPLATE for current requirements to determine wire size to be used for electrical hookup. When the cuber and the remote condenser are connected, each must be grounded to the other using the ground screws provided in the respective junction boxes. The cuber then requires a solid chassis to chassis earth ground wire. See Wiring Diagram. Be certain the cuber is connected to its own electrical circuit and individually fused. Voltage variation should not exceed ten percent of the nameplate rating, even under starting conditions. Low voltages can cause erratic operation and may be responsible for serious damage to the icemaker. The remote condenser is designed to be powered from the ice machine. There is a separate electrical junction box at the back of the ice maker for the remote condenser. Wire the remote condenser to the ice maker in accordance with local and national electric codes. All outdoor wiring must be in rainproof conduit. The condenser fan motor will run whenever the compressor is running. Electrical connections are made at the rear of the icemaker, inside the junction box. All external wiring should conform to the national, state and local electrical code requirements. Usually an electrical permit and services of a licensed electrician will be required. GROUND SCREW ELECTRICAL CONNECTIONS DETAIL OF JUNCTION BOX, 3 PHASE SHOWN HAND DISCONNECT SWITCH INTERCONNECTING WIRES POWER SUPPLY REMOTE CONNECTION September 1993 Page 7 CMS1202R FOR THE PLUMBER The recommended water supply line is a 3/8-inch O.D. copper tubing with a minimum operating pressure of 20 PSIG and a maximum of 80 PSIG. Connect to cold water supply line with standard plumbing fittings, with shut off valve installed in an accessible place between the water supply and the cuber. ln some cases a plumber will be required. Water Limitations: An ice machine is a food manufacturing plant, it takes in a raw material, water, and turns it into a food product, ice. The purity of the water is very important in obtaining pure ice and in maximizing product life. Even though there isn’t one filter that will cure all water problems, a good filter combined with a polyphosphate feeder gives about the best overall performance. POTABLE WATER SUPPLY DRAIN Connections: All drains are gravity type and must have a minimum of 1/4-inch fall per foot on horizontal runs. The drains to be installed to conform with the local plumbing code. Install a vertical open vent on drain line high point to insure good draining. The ideal drain receptacle is a trapped and vented floor drain. Recommended bin drain is 5/8 inch O.D. copper tubing and should be vented and run separately. Insulation for high humidity areas is recommended. The ice machine sump drain is 3/4" FPT. There must be a vent at this connection for proper sump draining. SUMP DRAIN MUST BE VENTED 3/4" FPT HAND SHUT OFF VALVE OPTIONAL FILTER 3/8" MALE FLARE VENT BIN DRAIN AIR GAP BETWEEN DRAIN LINES AND BUILDING DRAIN WATER SUPPLY AND DRAIN CONNECTION September 1993 Page 8 CMS1202R FINAL CHECK LIST 1. Is the cabinet in a room where ambient temperatures are within the minimum and maximum temperatures specified? 2. Is there clearance at the left and back sides of the cabinet for service access? 3. Has water supply pressure been checked to insure a minimum of 20 PSIG and a maximum of 80 PSIG operating pressure? 4. Is the cabinet level? 5. Check that any shipping material has been removed from inside the cabinet. FINAL INSTALLATION 6. Check that the reservoir is properly secured to the bottom of the evaporator plates. 7. Have all electrical, water and drain connections been made? 8. Is the water supply line shut off valve installed and electrical wiring properly connected? 9. Check all refrigerant lines and conduit lines, to guard against vibration or rubbing and possible failure. PRECHARGED LINES CONNECTED 10. Have the bin and cabinet been wiped clean? 11. Has the Manufacturers Registration form been properly filled out? Check for correct model and serial numbers from Serial nameplate, then mail to the SCOTSMAN factory. 12. Has the owner/user been given the Service Manual and instructed how to operate and maintain the icemaker? 13. Has the owner been given the name and telephone number of the authorized SCOTSMAN Service Agency serving him? LEVEL ASSEMBLY SUMP DRAIN HAND SHUT OFF VALVE OPTIONAL FILTER BIN DRAIN September 1993 Page 9 CMS1202R INITIAL START UP Before Start Up: FRONT VIEW OF TIMER 1. Check that the ICE-OFF-WASH rocker switch and the Compressor ON-OFF switch are in the OFF position. 2. Switch on the electrical power. Electrical power must be supplied to the ice machine for 12 hours before starting the compressor for the first time. The crankcase heater will now warm up the compressor’s oil. The oil is warmed to evaporate any refrigerant that may have collected in it. If there is refrigerant in the oil when the compressor starts, the oil will foam and will not lubricate the compressor properly, shortening its life. ACTUATOR BUTTON MICROSWITCH CAM HARVEST PORTION Do not start the compressor for the first time unless the dome of the compressor is warm. Start Up: 1. Remove front panel(s) by removing screws at the base and pulling out. 2. Remove two screws and the control box cover. FREEZE PORTION 3. OPEN the water supply line shut off valve.. 4. Open the “king” valve on the receiver. 5. Inside the control box is the shaft of the timer and the switch assembly. Rotate the shaft of the timer and switch assembly clockwise until the actuator arm on the microswitch drops off outer cam into cam slot. See “Front View of Timer”. CONTROL BOX 6. Move the ICE-OFF-WASH to the ICE position. 7. Check the water fill cycle: For several minutes the inlet water valve will be open and water will flow into the reservoir. Near the end of the fill cycle, water should be overflowing the reservoir and draining thru the reservoir drain. If at the end of the fill cycle the reservoir is not full, repeat step 5. Check that the sump covers are snapped in place. Check that the water distributors are properly seated at the top of the evaporators, and that water is flowing over all cube cells. CUBE SIZE CONTROL Note: Some water spray from the evaporators is normal when the machine is new. The spray will quit after a few cycles. 8. When the sump has filled, move the compressor ON-OFF toggle switch, to the ON position. TIMER ICE/OFF/WASH BIN ICE LEVEL SWITCH September 1993 Page 10 CMS1202R INITIAL START UP 9. Check operation of the freezing cycle: Ice will begin to from from the top of the evaporators down. After the first cycle, freezing time will range between 12 and 15 minutes. Longer time for temperatures above 70oF. and shorter time required when temperatures are below 70oF. Average complete cycle time is about 16 minutes. CUBE SIZE DIAGRAM JUST RIGHT 10. After an ice harvest, check Cube Size. There is just enough water available in the reservoir to When the cubes are the correct size, they will be make one full sized batch of cubes. As the water connected together vertically, and drop off in strips. level falls, the water pump may pick up some air at The batch weight will be about 13.5 to 14.5 lb. the end of the freezing cycle, so bubbles in the Note: If the cubes at the bottom rows of some evaporators pump discharge tube at the end of freeze is are smaller than others, the size difference does not affect normal. If the water pump runs out of water before capacity or performance. However, there should be some the end of freeze, the cube size control may be set ice in all cells. If not, contact the Factory. too cold, or the water system may be leaking water. Compare cube size to the "Cube Size Diagram" To adjust cube size, locate cube size control in the front of the control box, and rotate the adjustment screw one eighth of a turn: TOO SMALL • COUNTER Clockwise for a SMALLER cube • Clockwise for a LARGER ice cube Observe size of the ice in the next ice cube harvest and repeat the adjustment until the correct ice cube size is achieved. CAM 11. Check Harvest Time. There must be enough time in harvest to defrost all the cubes, but not an excessive amount that will waste capacity. The length of the harvest cycle is determined by the timer cam positions. If needed, adjust the harvest time so that there are about 15 seconds of harvest time left after the last cube has fallen off the evaporators. Because harvest time varies with the water and air temperatures at the ice machine, colder air and water will result in faster ice making, but require longer harvest cycles. Do NOT adjust harvest time too short or the unit will not harvest all the ice. The harvest time is set by: loosening the set screw on the cam, rotating the shaft so that the opening between the cams increase or decrease, retightening the set screw when the cams are in the correct position. More of an opening between the cams high areas= more harvest time. An adjustment of the cube size control may be needed after the harvest time has been changed, so check cube size again. ADJUSTING HARVEST TIME SET SCREW 12. Check Bin Ice Level Control: With the unit in the harvest cycle, place something directly below the transducer socket (located in the base just to the left of the evaporators). The machine will switch off at the END OF THE HARVEST CYCLE. Within seconds after removal of the obstruction, the icemaker will restart. This control has two positions, FULL and PARTIAL. Full shuts off when ice is 8" from the bottom of the ice machine. The control will not work on bins taller than 8’. 13. Replace all covers, panels and screws. 14. Fill out and mail in the Warranty Registration and Customer Evaluation form. Explain to the owner/user the operation, and maintenance requirements of the machine. Be sure to leave the name and telephone number of the local SCOTSMAN Distributor, or service agency. September 1993 Page 11 CMS1202R FREEZING CYCLE OPERATION Water from the sump assembly is pumped to the water distributor system at the top of each evaporator plate. From the water distributor the water cascades by gravity over all cells of the plate and to the sump assembly below. At the beginning of the freezing cycle, the electrical circuit is completed to the compressor and the water pump. The water pump operates continuously, through both the freezing cycle and the harvest cycle. During the freezing cycle, the hot gas solenoid valve is CLOSED and the water inlet solenoid valve is CLOSED. When the ice cubes are partially formed, the cube size control will sense the temperature at which it is preset to CLOSE. This will complete the electrical circuit to the timer. The timer then controls the remainder of the freezing cycle. The timer will keep the icemaker operating in the freezing cycle for a selected length of time. This will give the ice cubes time to fully form. after that selected length of time, the timer will switch the icemaker into the harvest cycle, through the contacts of the timer assembly microswitch. Low Temperature Freeze: When the outside air temperature is low, the Head Pressure Regulator will close off the liquid line to the receiver, causing liquid refrigerant to back up into the condenser unitl the head pressure builds up to 220 PSIG. While this is occuring, the head pressure regulator passes discharge gas into the receiver to keep the refrigerant flowing. WATER DISTRIBUTION INLET WATER VALVE DRAIN RESERVOIR WATER SCHEMATIC REFRIGERATION SCHEMATIC September 1993 Page 12 CMS1202R HARVEST CYCLE - HOT GAS BYPASS When the timer switches the icemaker into the harvest cycle, high pressure, high temperature gas refrigerant being discharged from the compressor is diverted from the condenser through the hot gas solenoid valve into each evaporator plate. During this cycle, the refrigerant bypasses the condenser. ln the electrical circuit, both the compressor and the water pump are operating and the hot gas solenoid valve is energized and OPEN and the water inlet solenoid valve is OPEN. The finished ice cubes are released from the sides of each evaporator plate by the warming effect of the hot gas condensing in each evaporator plate and the water cascading over the ice cubes. The released ice cubes drop into the ice storage bin below. At the end of the harvest cycle, the timer cam will push the actuator arm to the microswitch IN. If the ice level control is still CLOSED, a whole new cycle will begin. If the ice level control is OPEN, the icemaker will begin to shut OFF. Pump Down Cycle: When the ice level control is open at the end of the harvest cycle, power is removed from the liquid line valve coil, and the pump down cycle begins. The compressor will continue to run until the pump down control, sensing low side pressure, opens at 20 PSIG. WATER DISTRIBUTION INLET WATER VALVE RESERVOIR DRAIN WATER SCHEMATIC REFRIGERATION SCHEMATIC September 1993 Page 13 CMS1202R COMPONENT DESCRIPTION Cube Size Control Timer - Timer & Switch Assembly This reverse acting thermostat controls the length of the freezing cycle. It is sensing the temperature of the suction line. When the suction line gets cold enough, the cube size control closes (on temperature fall) and starts the timer. A change in either ambient air or incoming water temperature will affect the efficiency of the refrigeration system, and this will vary the length of time it takes the evaporator to reach the temperature at which the cube size control is preset to close. See CUBE SIZE ADJUSTMENT BEFORE attempting to adjust the control. The function of the timer begins when activated by the cube size control. The outer surface, or large diameter lobe of the timer cam, determines the timer cycle for finish freezing of the ice cubes, while the inner surface, or small diameter lobe, determines the time cycle for the harvest cycle. Relay The multi-function, three pole, double throw, plug-in relay is installed directly into a receptacle on the printed circuit board in the control box. The relay functions in part to by-pass the bin thermostat control to prevent the icemaker from shutting OFF, when the bin thermostat opens during the freezing cycle. The bypass action serves to ensure full-sized ice cubes with each harvest cycle. When the microswitch button is pushed in there is power connected to the coil of the relay, and the unit is in the freeze cycle. When the microswitch button is released, the power to the relay is stopped, and the unit goes into harvest. The microswitch is actuated by a cam assembly directly connected to the timer motor. One complete rotation of the cam will take eight minutes. Harvest is preset at three and one half minutes, but is adjustable. High Pressure Safety Control This is a manual reset control that shuts down the icemaker, should the discharge pressure ever reach 400 PSIG. Located below the control box. Low Pressure Control (Pump Down) This pressure control connects power to the compressor contactor coil. Its Cut In is 35 PSIG and its Cut Out is 20 PSIG. Located below the control box. CONTROL BOX CUBE SIZE CONTROL RELAY TIMER & SWITCH September 1993 Page 14 CMS1202R COMPONENT DESCRIPTION Bin Level Control This electronic control uses sound waves to measure the distance between the bottom of the ice machine and the top of the ice in the bin. It is designed to control the machine’s ice production to maintain that distance. The control is adjustable so that the ice machine will maintain a certain height of ice. When set at FULL it will not allow the machine to fill the bin any closer to the ice machine than about 8", and it will not work if the distance to the bottom of the bin is greater than 8 feet. Because it uses sound waves, a slight “ticking” sound can be heard coming from the bottom of the machine. There are three parts to the control, the transducer, the circuit board, and the ice level control switch. ICE/OFF/WASH SWITCH BIN ICE LEVEL SELECTOR SWITCH THE USER CAN SELECT THE AMOUNT OF ICE TO BE MAINTAINED IN THE BIN. SOUND WAVES FULL PARTIAL September 1993 Page 15 CMS1202R COMPONENT DESCRIPTION Water Inlet Solenoid Valve Hot Gas Solenoid Valve The water inlet solenoid valve fills the sump assembly with water and excess water overflows out the standpipe and down the drain. This action fills and rinses the sump during each harvest cycle. The flow rate is 1 g.p.m. The hot gas solenoid valve functions only during the harvest cycle, to divert the hot discharge gas from the compressor, by passing the condenser, for direct flow in the evaporator plates to release ice cubes from the ice cube molds. The hot gas solenoid valve is installed in a branch of the discharge line. When the harvest cycle begins the energized solenoid coil lifts the valve stem within the valve body, to cause the hot discharge gas to be diverted to the evaporators. Water Distribution System The water distribution system evenly supplies water to all cells of the evaporator plates. The water pump pumps water from the sump up the vertical tygon tube to the tee. From there water is channeled through the water manifold to the water distributors, above each evaporator plate, and from six holes within each distributor, water flows to the cells of each side of the evaporator plates. Gravity flow returns the unfrozen excess portion of water to the sump reservoir for recirculation. Strainer A water strainer is located in the potable inlet water line before the water inlet solenoid valve. Clean the water strainer frequently. WATER DISTRIBUTORS SUMP STAND PIPE OPTIONAL WATER FILTER HAND VALVE SUMP PUMP COMPONENT LOCATION September 1993 Page 16 DRAIN CAP CMS1202R CLEANING ///////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////// A Scotsman Ice System represents a sizable investment of time and money in any company’s business. In order to receive the best return for that investment, it MUST receive periodic maintenance. Maintenance and Cleaning should be scheduled at a minimum of twice per year. ///////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////// 7. Pour the cleaning solution into the reservoir until CLEANING: ICEMAKER full. 1. Remove screws and the front panel. 2. Switch the compressor switch to OFF. Switch 8. Move the master switch to the WASH position. 9. Let the unit operate for 30 minutes. Electrical Shock Hazard. Electrical shock can cause personal injury. Cleaning procedures are done with the power ON. the ICE-OFF-WASH rocker switch to OFF. 3. Remove the control box cover, and rotate the shaft of the timer and switch assembly CLOCKWISE advancing to the freezing cycle. (Beginning of the higher part of the cam against the microswitch). 4. Open the ice storage bin door and discard all the ice. 5. Remove the hose clamp, rubber cap and drain all the water from the sump assembly into the bin. Replace the rubber cap and hose clamp. 6. Mix 24 ounces of Scotsman Ice Machine Cleaner with 2 gallons of warm (950F. - 1150F.) water. Scotsman Ice Machine Cleaner contains acids. These compounds may cause burns. If swallowed, DO NOT induce vomiting. Give large amounts of water or milk. Call Physician immediately. In case of external contact, flush with water. KEEP OUT OF THE REACH OF CHILDREN. During the wash cycle, if the machine runs out of solution, mix 2 more gallons of solution per step 6, refill the sump and continue the wash cycle for the remainder of the 30 minutes. 10. Move the ICE-OFF-WASH switch to the OFF (center) position. 11. Remove the cap and drain the cleaning solution from the sump. Replace the drain cap. 12. Rotate the shaft of the timer and switch assembly CLOCKWISE to the harvest position (low part of the cam against microswitch). Move the ICE-OFF-WASH switch to the ICE position to start the Harvest cycle. If after completing this procedure one or more evaporator plates does not have a full flow of water for each vertical column of cubes, shut down the operation and remove and clean all water distributor manifolds. Reinstall the water distributor manifolds. Note: The ice making portion of the water system should be sanitized after cleaning by repeating steps 2-12 and substituting a sanitizing solution for the cleaning solution. 13. Move the compressor switch to the ON position to start the icemaking process. ///////////////////////////////////CAUTION/////////////////////////////// DO NOT use ice produced from the cleaning solution. Be sure none remains in the bin. /////////////////////////////////////////////////////////////////////////////////// 14. Check the next ice cube harvest to be certain that the ice cubes are clear and the acid taste is gone. 15. Add hot water to the bin to melt the ice. 16. Replace all panels. September 1993 Page 17 CMS1202R CLEANING Remote Condenser To remove scale: 1. Shut off the ice machine. 1. Mix a cleaning solution of 4 ounces of Scotsman Ice Machine Cleaner to 4 pints of hot (950 F. to 1100F.) water. The fan blade can cause personal injury. Disconnect power before beginning to clean condenser. Scotsman Ice Machine Cleaner contains acids. These compounds may cause burns. If swallowed, DO NOT induce vomiting. Give large amounts of water or milk. Call Physician immediately. In case of external contact, flush with water. KEEP OUT OF THE REACH OF CHILDREN. 2. Remove dirt and debris that might be under the condenser. 3. Brush off the bottom of the condenser fins. Do not use a wire brush. 4. Check to see that the inside of the condenser is clean; light should be visible through the fins. If not, clean the internal parts by vacuum, pressure washer and/or coil cleaner. Ice Storage Bin The interior liner of the bin is in contact with a food grade product: ice. The storage bin must be cleaned regularly to maintain a sanitary environment. Once a week cleaning with soap and water, a hot water rinse and and air dry is a basic procedure. Scale that may form on the plastic liner of a bin may be removed by scrubbing the surface of the line with a mixture of Scotsman Ice Machine Cleaner and hot water. Remove any scale prior to sanitizing. Note: Some ice storage bins have Stainless Steel liners. They may become stained from chlorine gases released from the water. These stains must be removed by regular cleaning to prevent pitting of the metal liner. To prevent the staining, an activated charcoal filter should be added to the ice machines incoming water supply line; activated charcoal removes the chlorine. This may require more frequent sanitation. 2. Remove all ice from the bin. 3. Using rubber gloves, dip a nylon scouring pad into the cleaning solution, and scub the scale off of the liner. 4. After the scale has been removed, rinse all of the surfaces inside the bin with clean, potable water. To sanitize the bin and ice machine: Follow local codes for frequency of sanitizing. Use an approved sanitizer and follow the directions and warnings of that santitizer or use the following instructions for use of household bleach, if it meets local codes: 1. Remove all ice from the bin. 2. Mix a sanitizing solution of 1 ounce of household bleach to 2 gallons of water. 3. Using clean rubber gloves and a clean cloth, wipe all interior surfaces of the ice machine and ice storage bin with the sanitizing solution. Immerse any small parts in the sanitizing solution and wash the parts, flushing the solution thoroughly in, over and through all parts and surfaces of the parts being cleaned. 4. Allow to air dry. September 1993 Page 18 CMS1202R SYSTEM SPECIFICATIONS The following numbers can be used as a guideline. There will be some variation from unit to unit. Typical Cycle Time • 17 minutes @ 70oF. air and 50oF. water; 20 minutes @ 90oF. air and 70oF. water. Typical Harvest Ice Weight • 13-14 lbs. Typical Low Side Pressure • 21-22 PSIG @ 70oF. air and 50oF. water • 24 PSIG @ 90oF. air and 70oF. water Typical Freeze Cycle Discharge Pressure • 250 - 210 PSIG Refrigerant Charge • 256 ounces of R-22 Harvest Time • Preset at 3.5 minutes, may be adjusted to suit local conditions Typical Suction Pressure in Harvest • 65-70 PSIG @ 70oF. air and 50oF. water • 80-85 PSIG @ 90oF. air and 70oF. water. Typical Discharge Pressure in Harvest • 75-80 PSIG @ 70oF. air and 50oF. water • 100 PSIG @ 90oF. air and 70oF. water. Typical Compressor Amp Draw Single phase • Beginning freeze = 11-12, End of Freeze = 8-9, Harvest = 9-10 Three phase • Three phase amps vary between 6 and 10 High Pressure Cut Out • Cuts out at 400 PSIG, manual reset Compressor • Copeland CRG3-0250-PFV-270 (single phase) • Copeland CRG3-0250-TF5-270 (three phase) Ice Level Control • Maximum Range = 8 feet Timer • 1 revolution takes 8 minutes Cube Size Control • Cut In adjustable between 0oF. and +250F. September 1993 Page 19 CMS1202R ADJUSTMENTS To Adjust The Timer & Switch Assembly: MICROSWITCH Electrical power present in the control box can cause personal injury. Disconnect power before beginning to adjust timer. Adjustment Of The Timer & Switch Assembly One complete revolution of the cam on the timer takes eight minutes. The normal setting is three and one-half minutes, as set at the factory. lt is important that the length of the harvest cycle allow enough time for all the ice cubes to fall from the evaporator. Too short of a time will cause the evaporator to freeze up and stop ejecting ice into the bin. Too much time wastes icemaking capacity, energy and water. Adjustment of the harvest cycle may require a corresponding adjustment of the cube size control. Rotating the shaft of the timer cam clockwise will allow putting the machine into either the freezing cycle or harvest cycle, as required in the cleaning instructions. CLOSE UP VIEW OF TIMER SWITCH ACTUATOR CAM The length of the harvest cycle can be changed by loosening the set screw on the cam, and then rotating the shaft so that the opening between the cams change. More of an opening between the cams = more harvest time. TIMER CAM ADJUSTING TIMER September 1993 Page 20 CMS1202R SERVICE DIAGNOSIS: Water SYMPTOM POSSIBLE CAUSE PROBABLE FIX No ice is made Inlet water valve will not open or is dirty Clean inlet screen, check coil, replace valve if required No water being pumped over evaporators. Check pump motor, replace pump if motor will not run. No water in reservoir, check inlet water valve, check reservoir for leak. Water inlet valve leaks thru at high rate Replace inlet water valve Cubes are not uniform in shape Water distributors are dirty Clean water system Long Freeze Cycle Inlet water valve leaks through Replace inlet water valve See electrical/adjustment See electrical/adjustment Water inlet valve restricted Clean or replace valve Low water pressure Check water filter or supply Sump covers out of position Re-position sump covers Inlet water valve leaks through Replace inlet water valve See electrical/adjustment See electrical/adjustment Makes thick ice/freezes up Cubes too large Low Capacity Unit runs out of water Incoming water very warm Check water temperature to building Lack of water See unit runs out of water Reservoir leaks Repair leak Inlet water valve restricted Clean or replace valve Short harvest cycle Adjust timer Water pressure too low Check supply September 1993 Page 21 CMS1202R SERVICE DIAGNOSIS: Electrical and/or Adjustments SYMPTOM POSSIBLE CAUSE PROBABLE FIX Machine does not operate No power Reconnect power High pressure control open Reset, check machine High temperature cut out open Hot gas valve leaks thru, replace P. C. Board Open Replace board Master switch open Test/replace Timer contacts open Replace timer Bin ice level control holding machine off See page 24 Makes thick ice/freezes up Runs, makes no ice Harvest Cycle too short Adjust timer Low water pressure Check water filter or supply Hot gas valve defective Replace hot gas valve Sump covers out of position Re-position sump covers Cubes too small Adjust cube size Cube size control stuck open Replace cube size control Pump problem or water leak in reservoir Check water system and pump Water inlet valve either lets in no water or leaks through Replace inlet water valve Timer stuck Replace timer Relay does not energize; unit stuck in Replace relay harvest Long freeze cycle Water inlet valve leaks through Replace inlet water valve Water temperature too high Advise user Cubes too small Cube size set wrong Adjust cube size Cubes size control stuck closed Replace cube size control Cubes too large Water inlet valve leaks through Replace inlet water valve and adjust cube size control Compressor cycles on and off on pump down control Low refrigerant charge Locate leak, repair, replace drier, evacuate and weigh in nameplate charge. Liquid line valve or drier restricted Check and replace TXV restricted Check and replace Head pressure control valve not working (low condensing temp.) Check/replace head pressure control valve Low pressure control will not close Check pump down control for proper operation Compressor will not run Unit cycles on and off anytime in any cycle Contactor coil open Check/replace contactor Compressor windings open Check replace compressor Loose connection in PC board Replace PC board September 1993 Page 22 CMS1202R SERVICE DIAGNOSIS: Refrigeration and/or Mechanical SYMPTOM POSSIBLE CAUSE PROBABLE FIX Poor harvest Hot gas valve does not open Check for power to the coil, check for not opening, replace Head pressure control valve does not Replace head pressure control valve. maintain enough head pressure. Unit cycles off during freeze or harvest Hi temperature switch opens and closes Hot gas valve leaks thru, replace it Low capacity High head pressure, from dirty condenser, faulty fan motor Clean condenser, repair fan motor Non condensable gas in the system Purge system, evacuate and weigh in nameplate charge Extreme hot location Relocate the cabinet Overcharge of refrigerant Evacuate and weigh in nameplate charge Hot gas valve leaks thru At the end of the freeze cycle there should be frost on the evaporator end of the hot gas tubes, if not replace the hot gas valve Liquid and discharge lines are in contact with each other Separate and insulate them Unit shuts off before bin is full Bin Ice level control is set to “Partial” Move bin Ice level rocker switch to “Full”. Compressor cycles on and off Low pressure control opening and closing Check low side pressure, liquid line valve must open and low side pressure raise over 35 PSIG before pump down control will close to run compressor Compressor overheats TXV not letting enough refrigerant into evaporators, adjust or replace TXV Mechanical fault with compressor, replace compressor Frost on compressor Some frost will not hurt Do nothing TXV meters too much refrigerant Adjust or replace TXV September 1993 Page 23 CMS1202R SERVICE DIAGNOSIS: Bin Ice Level Control CONDITION DETERMINE CAUSE PROBABLE CORRECTION Ice Machine does not run, it has power to it, the high pressure control is closed, the on/off switch is set to ON (the compressor will not operate until the liquid line valve opens, but the pump should be working if there is no ice in the bin). A. Listen for a ticking sound from transducer. If no noise, go to C. If there is a noise, check for a light on the board (models built after 4/93). If there is a light on, check relay contacts N.O. and COM. The contacts should be CLOSED. If closed, go to D. If not, replace the board. If light is off, or prior model, go to B. B. Remove front panel(s), twist transducer 1/4 turn and pull out. DO NOT UNPLUG with power connected. Examine the transducer, the inside must be clean and dry. If the inside of the transducer (above screen) was wet, replace it. Set bin level to FULL and aim at an object about 1-3 feet away. Machine should restart, if not go to D. C. Check power to bin level control Should be 12 volts from transformer, board. if not replace transformer. If there is power go to D. D. Disconnect electrical power and test ice machine circuit by attaching a jumper wire between bin thermostat posts on circuit board part no. 12-1912-01 (the circuit board with the timer on it). Reconnect power. If machine does not start go back to machine circuit. If machine starts, disconnect electrical power, remove jumper wire and reconnect electrical power. Then go to E. E. Transducer or ice level board assembly defective. Replace transducer. Set bin level to FULL and aim at an object about 1-3 feet away. Machine should restart. If this does not repair unit, replace the board. Machine runs, makes ice, switches on and off, but ice level cannot be controlled. Ice level switch may be defective. On Replace ice level switch boards with a light, check by moving switch & watching light. Machine runs, but will not shut off. Board relay stuck closed. Check relay. PARTIAL VIEW OF CIRCUIT BOARD 12-1912-01 PLUG - IN RELAY TIMER If COM and N.O. are closed when power is off, replace board. If open, go to B above. Electrical Shock Hazard Can Cause Personal Injury. Disconnect Power Before Servicing. Bin Thermostat Posts at Line Voltage. BIN THERMOSTAT POSTS MENTIONED IN “D” ABOVE September 1993 Page 24 CMS1202R REMOVAL AND REPLACEMENT Cube Size Control To remove the cube size control: Electrical Shock Hazard. Electrical shock can cause personal injury. Disconnect power before beginning to service components. 1. Remove front panel. 2. Remove cover from control box. 3. Trace capillary tube, from the cube size control to the refrigerant suction line. NOTCH IN BACK OF CONTROL BOX Water Distributor Tubes And Manifold Tubes To remove the water distributor tube and manifold tube: 1. Remove the front panel. 2. Slide the water distributor tube to the front about 1/8-inch along the top of the evaporator plate, until the water distributor tube can be unsnapped from the flexible notch and lifted upward. WATER DISTRIBUTOR CUBE SIZE CONTROL REPLACEMENT OF THE CUBE SIZE CONTROL 4. Remove the coiled capillary tube bulb from the tube well on the suction line. 5. Remove electrical leads from the cube size control. 6. Remove screws and pull the capillary tube through the notch in the back of the control box. Remove the cube size control. To replace the cube size control, reverse the removal procedure. 3. Unsnap and disconnect water distributor tubes from the water manifold section. To replace the water distributor tubes and manifold tubes, reverse the removal procedure. BE SURE the notches in the water manifold tubes properly engage the alignment keys in the tee. BE SURE the water distributor tube is securely fastened at the notch at both sides of the evaporator plate. Check identical attachment for the left water distributor tube and notch; also, that the distributor/manifold connections at the top center of each evaporator plate is snug against the top of the plate. September 1993 Page 25 CMS1202R REMOVAL AND REPLACEMENT Inlet Water Solenoid Valve Assembly To remove the inlet water solenoid valve assembly: Electrical Shock Hazard. Electrical shock can cause personal injury. Disconnect power before beginning to service components. 1. Shut OFF water supply to machine. 2. Loosen and remove outlet water line from the inlet water solenoid valve assembly. 3. Remove screws and pull the water solenoid valve out to gain access. INLET WATER VALVE Water Pump 1. Remove front panel. 2. Unplug water pump electrical connection. STRAINER 3. Drain water reservoir. 4. Use corbin clamp pliers to loosen and slide corbin clamps on hoses away from pump. 5. Remove screws retaining pump to bracket. 6. Pull pump out of ice machine. 7. Reverse to reassemble. REMOVAL OF THE INLET WATER VALVE 8. Replace front panel. 8. Reconnect electrical power. Transducer 4. Pull electrical cord from solenoid coil terminals. 1. Disconnect electrical power BEFORE removing transducer. 5. Remove inlet water fitting from the water solenoid valve. To replace the inlet water valve assembly, reverse the removal procedures. 2. Remove front panel and locate the transducer socket. Bin Ice Level Control Circuit Board 3. Twist inner portion of transducer counter-clockwise and push up gently. 1. Disconnect Electrical Power before removing circuit board. 4. Unplug transducer and remove from the machine. 5. Reverse steps 1-5 to reassemble. 2. Remove front panel. 3. Remove control box cover. 4. Remove wires from circuit board connections. 5. Unlock circuit board fasteners by twisting 1/2 turn. 6. Pull circuit board of off fastener posts. 7. Reverse to reassemble, refer to wiring diagram as needed. September 1993 Page 26 CMS1202R REMOVAL AND REPLACEMENT Thermostatic Expansion Valve Hot Gas or Liquid Line Valve. 1. Before replaceing this valve, be certain that the valve is the cause of the problem, and cannot be adjusted. 1. Before replaceing this valve, be certain that the valve is the cause of the problem. 2. Remove the front panel. 3. Dischargeand recover the refrigerant. 3. Discharge and recover the refrigerant. 4. Unplug the coil of the valve. 4. Locate the TXV bulb (on the suction line), remove the clamps and bulb from the tube. 5. With the refrigeration system open, unsweat the valve from the tubing. 5. With the refrigeration system open, unsweat the TXV from the tubing. 6. Place the new valve in position. 6. Place the new TXV in position. 7. Wrap the new TXV body with wet rags. Do not get any moisture in the valve. 8. Carefully braze the valve to the tubing. Examine the joints, if they look good procede to the next step, if not, re-do them. 9. Install a new dryer, and braze it in place also. 10. Reattach the TXV bulb to the suction line in the same place as the old one. 11. Evacuate the system to 500 microns. 12. Weigh or measure the nameplate charge into the receiver. 13. If the machine has been off on the breaker there may be refrigerant trapped in the oil of the compressor, so do not restart until the compressor has been warmed by the crankcase heater for 12 hours. If the compressor was warm throughout the replacement process, the ice machine may be restarted without waiting to re-warm the compressor. 2. Remove the front panel. 7. Wrap the new valve body with wet rags. Do not get any moisture in the valve. 8. Carefully braze the valve to the tubing. Examine the joints, if they look good procede to the next step, if not, re-do them. 9. Install a new dryer, and braze it in place also. 10. Plug the power cord back onto the coil. 11. Evacuate the system to 500 microns. 12. Weigh or measure the nameplate charge into the receiver. 13. If the machine has been off on the breaker there may be refrigerant trapped in the oil of the compressor, so do not restart until the compressor has been warmed by the crankcase heater for 12 hours. If the compressor was warm throughout the replacement process, the ice machine may be restarted without waiting to re-warm the compressor. FRONT SEATED VALVE Refrigerant: NO liquid refrigerant may be put into this system anywhere except the receiver. DO NOT use the Schrader valves at the front of the machine for weighing in the charge: use the “king” or receiver service valve. All liquid R-22 must be weighed into the receiver through the “front seated” receiver outlet service valve. September 1993 Page 27 SERVICE PORT